1 / 28

Evolving Composites Simulation Requirements and Solutions

Evolving Composites Simulation Requirements and Solutions. John Klintworth MSC.Software Ltd. Industry Trends. Lower Carbon Fibre Costs Sheet Material Replacing Random Fibres Heavier Sheet Reinforcement Weights Fewer Plies for Required Performance New Markets, e.g. Automotive, Energy BUT:

bonner
Download Presentation

Evolving Composites Simulation Requirements and Solutions

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Evolving Composites Simulation Requirements and Solutions John Klintworth MSC.Software Ltd.

  2. Industry Trends • Lower Carbon Fibre Costs • Sheet Material Replacing Random Fibres • Heavier Sheet Reinforcement Weights • Fewer Plies for Required Performance • New Markets, e.g. Automotive, Energy BUT: • Manufacturing Difficulties • Need more manufacturing simulation • Less Redundant Material • Need more structural simulation

  3. Simulate Simulate Simulate Simulate Aero. Shape Zone Layup Ply Layup Ply Details Certification Manufacture feedback loop ... OK! Development Process

  4. Aerospace • Wheel cover • >100 Plies modelled in CAD • Transferred to CAE automatically • Benefits: • Correlation between CAD and CAE • Verification and failure tools in CAE

  5. Motorsport • Monocoque • > 1000 Plies, > 100K elements • Quick turnaround • Benefits: • Rapid modification • Manufacturing link • Failure analysis • Crash model

  6. Automotive • Floorpan • Cheap, heavy fabrics • Manufacturing critical • Benefits: • Predict producibility rapidly • Account for stiffness and strength of sheared material

  7. Marine • America’s Cup Yacht • High performance • Variable loading • Benefits: • Ply based model • Automated generation • Failure analysis • Manufacturing link Stress Contours under Upwind Loads By courtesy of Team NZ & Matrix Applied Computing Ltd.

  8. Energy • Wind Turbine Blade • Up to 40 m long • Lowest cost • Local buckling, flutter • Benefits: • Modify materials easily • Multiple analysis codes • Manufacturing data

  9. Leisure • Helmet • Fabric reinforcement • Sandwich construction • Must reduce cost • Benefits: • Simulate manufacture • Account for shear-induced thickening

  10. Simulation Drivers • Each industry has different structural requirements • These affect the degree of modelling and simulation used

  11. Modelling • Ply modelling used throughout industries • Rapid modification • Link to manufacture • Zone modelling used for preliminary sizing

  12. Manufacturing Simulation • Draping is now used universally • Forming only useful for extreme cases • Resin flow simulation in marine market • Curing limited to aerospace

  13. y M.o.S = (a-b)/b b a x Failure Surface in Stress Space Structural Simulation • Linear and failure analyses routine • Crash analyses emerging for motorsport, automotive • Durability needed but unresolved

  14. Optimization • Topology optimisation under research • Parametric techniques established for multidisciplinary optimisation • System optimisation growing

  15. Evolving Requirements • Larger Models • Better Verification • Automated Data Transfer • Mirroring/Rotation • Solid Analysis • Nonlinear Analysis • Crash & Crush Analysis • Quicker Sizing • Account for Material Shear

  16. Larger Models • Requirements • 200000 elements • 2000 plies • 20000 PCOMPS • 200 loadcases • Solutions • Remove bottlenecks • 2-1000 x faster

  17. Better Verification • Requirements • Audit model • Solutions • Show Layup • Element • Cross Section • Show Laminate

  18. Automated Data Transfer • Requirements • Speed up ply import • Import and export laminates • Export flow model • Solution • CAD Ply import 1000x faster • LAP interface • RTM-Worx interface

  19. Aero. Shape Zone Layup Ply Layup Ply Details Certification Manufacture LAP interface • Import materials and laminates during zone definition • Export materials, laminates and loads during certification

  20. RTM-Worx interface • Export materials, plies and layup • Both warp and weft directions considered • Simulate resin flow for RTM • Curing analysis

  21. ESAComp interface • Import materials and laminates during zone definition • Export materials, laminates and loads during certification

  22. Mirroring/Rotation • Requirement • Reduce modelling time for symmetrical structures • Solution: • Transform Layup Mirror

  23. Account for Material Shear • Requirements • Account for shear • Solution • Reference sheared material properties

  24. Solid Analysis • Requirements • Solid model for thermal analysis • Solution • Extrude solids • Calculate equivalent material • Create coordinate frames

  25. Nonlinear Analysis • Requirements • Support MSC.Marc • Solution • Update preference

  26. Element Failure Time Crash & Crush Analysis • Requirements • Support MSC.Dytran, LS-DYNA, Pamcrash • Solution • Update preferences

  27. Quicker Sizing • Requirements • Smeared Laminate • Discrete variables • Solution • In MSC.Nastran 2001

  28. Conclusions • Simulation drivers vary widely across industries • Ply modeling and kinematic draping are now universally accepted • Resin flow and curing simulation show potential • Crash and durability analysis developing rapidly • Formal optimisation methods promise improved sizing

More Related